Your logo

here
8D Investigation Report Additional free templates on :
www.mgt-tools.com
Revision : 05/06/2016

D0. Background D1 - Team

Date Customer Ref Internal Ref Rank A. Ardan 4567

A
Customer D. Martin 4568
Customer name F. Rodin 4569
Contact details 546-09 2009-056 K.Benamou 4570
Vehicle E. Tobin 4571
Plant / Workshop

D2 - Describe the problem

i. Customer description iii. Scope
Known concern ? Y/N
Other models/customers affected? Y/N
ii. Internal description
What? iv. Picture, Sketch
When?
Who? Where? How many?
How?
Why?
NG
µ Attachements : 0

D3 - Containment Actions
Location Affected Total Sorted NG Progress Visualization
S Incoming inspection Y/N 20 10 5 25
O Internal stocks Y/N 20
R Manufacturing process Y/N 15
T 10
I Finished Stocks Y/N
5
N Customer stock Y/N 0
G Customer side of line Y/N

NG
Sorted
Tota l

Customer yards Y/N

Overall 20 10 5
Item Lead Location Date Quantity Comments
C
O
N
T
A
I
N
'

D4 - Identify Root Cause, D5 - Implement countermeasures, D6 - Monitor

Item Root Cause (Cf. to Attachment) Counter Measure Action Lead Due Actual Check

D6 - Reccurence Prevention
Items Action Lead Due Status
DFMEA
PFMEA
Control Plan
Work Instructions
Measurement
Others
D7 - Congratulate the team Case closure follow-up
Date : Date of closure :
Lead : Agreed PPM / Cost:
Other agreements :
Ishikawa

[1] Material [2] Methods [3] Machines

1.1 Plastic cover material NG 2.1 Screwing order NOK 3.1 Screwdriver torque deviation
1.2 Screw material NG 2.2 No torque control 3.2 Injection parameters deviation
u 1.3 Screw dimension NG 2.3 Plastic injection param. NG 3.3 Screwing order not as planed
u 1.4 Plastic cover dimension NG 3.4 Poka Yoke not working

Plastic cover
Plastic cover
Missed operation 4.1 Deformation due to temp. 5.1 Torque wrench NG 6.1 loose
loose
Did not follow work instruction 4.2 Torque decrease due temp. 5.2
Cross-thread when screwing 4.3 Torque decrease due humidity 5.3

[4] Manpower [5] Environment [6] Measurement

Confirmation of ishikawa items

# Potential Cause Standard Actual Judg. Link Status Reference / Evidence
1.1 Plastic cover material NG ABS PC ABS PC OK No Closed Lab report #059
1.2 Screw material NG Steel XX Steel XX OK TBX
1.3 Screw dimension NG 5.0 +/- 0.1 5.08 OK TBC Med. Prior Tridim report #2010-089
30 +/- 0.2 30.03 OK No Low Prior. Tridim report #2010-090
1.4 Plastic cover dimension NG 4.1 +/- 0.2 4.5 NG Yes High Prior. Tridim report #2010-089
Confirmed screwing order cannot
2.1 Screwing order NOK 1>2>3>4 1>2>3>4 OK No Closed cause such issue

2.2 No torque control

2.3 Plastic injection param. NG
3.1 Screwdriver torque deviation
3.2 Injection parameters deviation
3.3 Screwing order not as planed
3.4 Poka Yoke not working PY should work PY is OK OK No Closed Confirmed PY is OK

4.1 Missed operation

4.2 Did not follow work instruction
4.3 Cross-thread when screwing
5.1 Deformation due to temp.
5.2 Torque decrease due temp.
5.3 Torque decrease due humidity
6.1 Torque wrench NG

Additional supporting materials

5W2H
What? What hapenned?
What is the problem ?
What is the scope of the problem ?
When? When did it happen ?
Which date / time ?
Which shift ?
Which season (if relevant) ?
When did it start ? When did it stop ?
Is it continuous problem ? Intermittent ?
Is it linked to a specific customer usage ?

Who? Who faced the problem ?

Who reported the problem ?
Who is the customer ? Who is the final customer ?
Who are the stakeholders ?
Who are the parties involved ?

Where? Where did it happen ?

Is it inhouse or at customer ?
Where is the stakeholders location ?
Which other location should be considered ?
Describe nearby locations (if relevant) ?

How many? How many parts were involved ?

How many (…) were injured (if applicable) ?
How many customers are affected ?

How? How did it happen ? (step by step explanation)

Can we reproduce it ?

Why? Why is it a problem ?

What is standard versus actual ?
Is it a must or nice to have ?
Pareto
Item Deffect Rate Cumulative
Item 1 11% 11% Pareto
96% 97%
Item 2 8% 19% 12%
88%
91% 94%
84%
Item 3 7% 26% 10% 77%
81%
73%
Item 4 7.0% 33% 65%
69%
8% 61%
Item 5 6.0% 39% 51%
56%
45%
Item 6 6.0% 45% 6%
39%
33%
Item 7 5.5% 51% 4% 26%
Item 8 5.0% 56% 19%
2% 11%
Item 9 5.0% 61%
11% 8% 7% 7% 6% 6% 6% 5% 5% 5% 4% 4% 4% 4% 4% 4% 4% 3% 2% 2%
Item 10 4.5% 65% 0%

Item 2
Item 3

Item 5
Item 6
Item 7
Item 8

Item 10
Item 11
Item 12
Item 13

Item 15
Item 16

Item 18

Item 20
Item 1

Item 4

Item 9

Item 14

Item 17

Item 19
Item 11 4.0% 69%
Item 12 4.0% 73%
Item 13 3.8% 77%
Item 14 3.8% 81% Pareto
Item 15 3.8% 84% 12% 91% 94%
96% 97%
88%
Item 16 3.5% 88% 77%
81%
84%
10% 73%
Item 17 3.5% 91% 65%
69%
8% 61%
Item 18 2.5% 94% 56%
51%
Item 19 2.0% 96% 6% 39%
45%
33%
Item 20 1.5% 97% 4% 26%
Item 21 1.5% 99% 19%
2% 11%
Item 22 1.0% 100%
11% 8% 7% 7% 6% 6% 6% 5% 5% 5% 4% 4% 4% 4% 4% 4% 4% 3% 2% 2%
0%
Item 4
Item 5

Item 11

Item 16
Item 17
Item 18
Item 1
Item 2
Item 3

Item 6
Item 7
Item 8
Item 9
Item 10

Item 12
Item 13
Item 14
Item 15

Item 19
Item 20
Pareto
96% 97%
12% 91% 94%
88%
84%
81%
10% 77%
73%
69%
65%
8% 61%
56%
51%
45%
6% 39%
33%
4% 26%
19%
2% 11%

11% 8% 7% 7% 6% 6% 6% 5% 5% 5% 4% 4% 4% 4% 4% 4% 4% 3% 2% 2%
0%
Item 4
Item 5

Item 11

Item 16
Item 17
Item 18
Item 1
Item 2
Item 3

Item 6
Item 7
Item 8
Item 9
Item 10

Item 12
Item 13
Item 14
Item 15

Item 19
Item 20
 reto
99% 100%
96% 97%
91% 94% 100%
88%
81%
84% 90%
77%
73% 80%
70%
60%
50%
40%
30%
20%
10%
4% 4% 4% 4% 4% 4% 3% 2% 2% 2% 1%
0%
Item 12
Item 13

Item 15
Item 16

Item 18

Item 20
Item 21
Item 14

Item 17

Item 19

Item 22

reto
100%
96% 97% 99%
91% 94% 100%
88%
84%
90%
81%
77%
73% 80%
70%
60%
50%
40%
30%
20%
4% 4% 4% 4% 4% 4% 3% 2% 2% 2% 1% 10%
0%
Item 16
Item 17
Item 18
Item 12
Item 13
Item 14
Item 15

Item 19
Item 20
Item 21
Item 22

reto
100%
96% 97% 99%
91% 94% 100%
88%
84%
90%
81%
77%
73% 80%
70%
60%
50%
40%
30%
20%
4% 4% 4% 4% 4% 4% 3% 2% 2% 2% 1% 10%
0%
Item 16
Item 17
Item 18
Item 12
Item 13
Item 14
Item 15

Item 19
Item 20
Item 21
Item 22
5 Why's
Ishikawa Diagram (Fishbone Diagram)

Man Material Methods

Text Text Text

Text Text Text Text
Text Text
Text Text Text Text
Text Text

Machine Environment Measurement

 Concern

Text
Text
Ishikawa Diagram (Fishbone Diagram)

[1] Material [2] Methods [3] Machines

.1 Plastic cover material NG .1 Screwing order NOK
.2 Screw material NG .2 No torque control
u .3 Screw dimension NG .3 Plastic injection param. NG
u .4 Plastic cover dimension NG

Missed operation .1 Deformation due to temp. .1 Torque w

Did not follow work instruction .2 Torque decrease due temp. .2
Cross-thread when screwing .3 Torque decrease due humidity .3

[4] Manpower [5] Environment

[3] Machines
.1 Screwdriver torque deviation
.2 Injection parameters deviation
.3 Screwing order not as planed
.4 Poka Yoke not working

Plastic cover
Plastic cover
Torque wrench NG loose
loose

[6] Measurement
FTA : Failure Tree Analysis
FTA : Failure Tree Analysis